ATSG INTRODUCTION TOYOTA - VOLVO A-40 SERIES The A-40 series of transmissions are covered in this manual. In the tear-down and assembly section we use ‘an A430 transmission. We refer to the different valve body configurations where applicable. Although the ‘A-40, 41 do not have the overdrive unit, the assembly is quite similar. ‘The A-40 series transmissions are found in Toyota and Volvo vehicles. The units have minor differences and carry different gaskets and seals. The Volvo unit may be referred to as the BW-55, NOT TO BE CONFUSED WITH THE A-55 (Tercel). We have illustrated the gaskets for the valve bodys in a separate section. This section also shows valve body disassembly. There have been many seal and gasket changes on these models. We advise you check the gaskets from the unit with the replacement gaskets to be sure that the correct ones are installed. ‘When diagnosing an A-40DE be sure to determine whether itis a computer complaint, transmission complaint or both. ifthe computer is not operating, the transmission should be able to shift manually. We thank the Toyota Motor Company for the illustrations and information that have made this booklet possible. ROBERT D. CHERRNAY DALE ENGLAND TECHNICAL DIRECTOR FIELD SERVICE CONSULTANT FRANK MIETUS WAYNE COLONNA TECHNICAL CONSULTANT TECHNICAL SUPERVISOR JIM DIAL PETE LUBAN TECHNICAL CONSULTANT TECHNICAL CONSULTANT ED KRUSE TECHNICAL CONSULTANT AUTOMATIC TRANSMISSION SERVICE GROUP 9200 S. DADELAND BLVD. SUITE 720 MIAMI, FL 33156 (305) 670-4161 1INDEX TROUBLE SHOOTING DISASSEMBLY .... COMPONENT GROUP ..... PUMP .... OVERDRIVE INPUT SHAFT ..... OVERDRIVE CASE FRONT CLUTCH .... REAR CLUTCH .......... CENTER SUPPORT PLANETARY GEAR SET .. TRANSMISSION CASE .... ASSEMBLY .. VALVE BODY/GASKETS .. TECHNICAL CHANGES IDENTIFICATION . Automatic Transmission Service Group 9200 South Dadeland Blvd. Suite 720 Miami, FL 33156 (305) 661-4161Technical Service Information TROUBLESHOOTING Problem Possible cause Remedy Fluid discolored or smels buret Fluid contaminated Torque converter faulty Transmission faulty Replace fluid Replace torque converter Disassemble and inspect transmission Vehicle does not move inany drive range Manval shift linkage out of adjustment \Valve body or primary regulator faulty Parking lock paw! faulty Torque converter faulty Converter drive plate broken Oil pump intake strainer blocked ‘Adjust shift linkage. Inspect valve body Inspect ing pawl Replace torque converter Replace torque converter Clean strainer Shift lever position Manual shift linkage out of adjustment Manual valve and lever faulty Transmission faulty ‘Adjust shift linkage Inspect valve body Disassemble and inspect transmission Harsh engagement into any drive range “Throttle cable out of adjustment Valve body or primary regulator faulty ‘Accumulator pistons faulty Transmission faulty ‘Adjust throttle cable Inspect valve body Inspect accumulator pistons Disassemble and inspect transmission Delayed 1-2, 2-3 oF 3-00 up-snift, or down shifts from 0-3 (or 3-2 then shifts back 10.00 or 3 Throttle cable out of adjustment Throttle cable and cam faulty Governor faulty Valve body faulty Slips on 1-2, 23 or 3-00 up-shitt, or slips or shudders on uakeotf Manual shift linkage out of adjustment Throttle cable out of adjustment Valve body faulty Transmission faulty ‘Adjust throttle cable Inspect throttle cable and cam Inspect governor Inspect valve body Adjust shift linkage Adjust throttle cable Inspect valve body Disassemble and inspect transmission binding or tie-up on 1-2, 23 or 30D upsshift Manual shift linkage out of adjustment ‘Valve body faulty ‘Transmission faulty ‘Adjust shift linkage Inspect valve body Disassemble and inspect transmission AUTOMATIC TRANSMISSION SERVICE GROUP